Мануал для 157 qmj

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GY6 150cc 157QMJ Service Manual

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TABLE OF CONTENTSGENERAL INFORMATION PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES ENGINE LUBRICATION SYSTEM FUEL SUPPLY SYSTEM
TRANSMISSION COMPONENTS ELECTRICAL STARTING SYSTEM BELT DRIVE CVT
MECHANISM CLUTCH REAR TRANSMISSION SYSTEM ELECTRICAL SYSTEM
IGNITION SYSTEM CHASSIS WIRING DIAGRAM INDEX 1 5 9 24 28 33 36 42
46 51 56 62 66 72 73

iii

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURESPERIODICAL CHECK AND
SERVICESThe maintenance intervals in the following table are based
upon average riding conditions. Riding in unusually dusty areas
requires more frequent servicing.Items Needing Servicing Tire
pressure/wear Brake performance Tightness of screws Air cleaner
Carburetor Spark plug Drive chain Brake uid Replace gearbox oil
Chassis Fuel switch/fuel tank Battery Engine oil Valve clearance of
engine Initial Service (rst week) I I I I I Monthly I I I C A I I
C, L I R A Quarterly Yearly

C C, A C, A, L I R L

I C

C I

A: Adjust C: Clean I: Inspect, clean or replace if necessary L:
Lubricate R: Replace

MAINTENANCE AND TUNE-UP PROCEDUREDescriptions of the servicing
procedures for each item in the Periodic Maintenance
requirements.

SPARK PLUGNote: The spark plug should generally be serviced when
the engine is cold. Clean up the carbon around the spark plug to
prevent it from dripping into the cylinder when being removed.
Remove the spark plug If the spark plug is too tight to remove,
spray rust inhibiter on the spark plug washer and the thread. After
soaking for a few minutes, the spark plug should easily unscrew.
Clean up any dirt and carbon accumulation on the spark plug with a
steel brush or a blade. Inspect the spark plug gap, it should be
about 0.6 ~ 0.7mm. When the carbon accumulation and wear of the
spark plug are too severe, replace the spark plug with one of the
same specication.5

FINAL GEAR OILNote: Inspect monthly and change quarterly. Note:
80/90 weight gear oil is recommended in the nal drive case.
However, in extreme cold weather conditions, you may notice that
the kart is hard to push. If that is the case, use lighter
viscosity oil, such as 75 weight or equivalent motorcycle
transmission uid. To check level, remove level screw on the left
rear engine case. To drain oil, remove the drain plug at the rear
bottom of the engine case. It is recommended to warm the engine for
10 minutes or more draining nal drive oil.

Final drive capacity 80ml 80/90 weight

ENGINE OILNote: Inspect before each use. Change monthly. Remove
the drain plug from the left side bottom of the engine. Drain into
oil pan for disposal. Remove the large cap on the right bottom of
the engine and remove the screen. Wash the screen with cleaning
solvent and ret, making sure the O-ring is still in good condition.
Rell the engine with 10W-40 engine oil and run for 5 minutes. Check
oil level on the ller cap stick to assure proper level. The cap
needs to be screwed in for a proper reading.

CHASSISGrease chassis bushings and bearings with grease
quarterly to assure smooth operation and extended lift of the
bushings and the components. If used in extreme wet and muddy
conditions or dusty conditions, greasing is recommended more
often.

CARBURETORRefer to Carburetor section.

VALVE CLEARANCERefer to Engine section.8

ENGINEENGINE COMPONENTS INSPECTION AND SERVICING ENGINE
COMPONENTS AND CRANK CONNECTING ROD MECHANISM INSPECTION AND
SERVICING

ENGINE COMPONENTS: CYLINDERCYLINDER REMOVALThe removal can be
done on the vehicle body. Remove cylinder head. Remove cylinder.
Remove cylinder gasket, bolts Erase cylinder gasket. Caution! Do
not damage the cylinder area. Make sure not to drop anything,
including cylinder gasker material into the crankcase.

CYLINDER INNER WALL WEAR INSPECTIONUse a bore diameter dial
gauge to measure the degree of wear. The measure point is divided
into three sectional planes in the axial direction: upper, middle
and lower; measure every plane each time on the mutually
perpendicular directions (X, Y), the measured least dimension is
the cylinder bore; at the most upper position measured is the
largest diameter, and the lowest position measured is the smallest
diameter, their difference is the cylindricity of the cylinder. At
the same cross section, measured the difference of diameter between
two points mutually perpendicular; which is the circularity of the
cylinder. In order to make the measuring point perpendicular with
the bore axis of the cylinder, and to ensure the precision of the
measurement, the bar of the gauge can be slightly swung in the
direction of the gauge bar, and take the smallest reading number as
the result. In the situation without a dial gauge, a feeler gauge
can be used to make relativity measurement, that is to put a new
piston into the cylinder, and use the feeler gauge to measure the
gap between the piston skirt and the cylinder wall, then gure out
the abrasion loss of the cylinder. If the circularity of the
cylinder exceeds the limit, then a cylinder reboring machine should
be used to rebore the cylinder, and enlarge its diameter by 0.5mm
or 1.00mm, then t the piston and piston ring which size are also
enlarged. If the wear is too severe and cannot be reworked, then a
new cylinder should be installed.Cylinder bore Cylindricity
Circularity 57.4mm 0.05mm 0.05mm

9

CRANK CONNECTING ROD MECHANISM: PISTON SETPISTON PIN INSPECTION
AND SERVICING Insert the piston pin horizontally into the piston
pin hole, and inspect the clearance between piston and piston
pin.Service Limit 0.02mm

If the free play is too much, the worn condition of piston pin
and piston pin hole must be inspected respectively. Measure the
external diameter of piston pin.Service Limit 14.98mm

If the result is less than the Service limit, it should be
replaced. After replacement, check the clearance between piston pin
and piston pin hole and make sure it complies with the required
measurement. Measure the inner diameter of piston pin.Service Limit
15.02mm

If the result is more than the service limit, it should be
replaced. After replacement, check the clearance between the holes
of the piston pin and make sure it complies with the required
measurement.

PISTON RINGS INSPECTION AND SERVICING Inspect the piston ring
for aws, serious wear, or serious conglutination, etc. If there is,
it should be replaced. If the piston rings lateral clearance and
notch clearance are too large or too small it will cause
malfunctions, so it must be measured. Measure the clearance of the
piston ring in the piston ring groove. This clearance is the piston
rings lateral clearance.First Ring Second Ring 0.09mm 0.09mm

CONNECTING ROD END INSPECTION Put the piston pin and bearing
into the connecting rod end; inspect the degree of tightness of the
piston pin in connecting rod end. Measure the inner diameter of the
connecting rod end.Service Limit 15.06mm

When the abrasion of the bore exceeds the limitation, it should
be replaced.10

PISTON RINGS SET UPBefore setting up, apply oil on each piston
ring, then enlarge piston rings; at the same time put them on the
piston and move downwards gradually, until piston rings fall into
the ring groove.

PISTON SET INSTALLATION Remove the gasket attached to the
crankcase. Mount piston onto the small end of the connecting rod.
The top of the piston marked with IN should be mounted towards the
direction of the inlet port (if the mark is EX, then it should be
mounted towards the direction of the exhaust port). Mount piston
pin and piston pin clip Apply oil on the piston pin to lubricate
it. Cover the crankcase port with a piece of cloth to keep the
piston clip from dropping into the crankcase.

CRANK CONNECTING ROD SETThe connecting rod is the component that
links the piston and crank. The picture shows the structure and
assembling relations of the crank connecting rod component.

CRANKCASE AND CRANKSHAFT REMOVALBefore removing the crankcase
and crankshaft, follow these procedures: Remove the engine. Remove
the cylinder cover. Remove the cylinder. Remove the piston. Remove
the drive plate and the driven plate. Remove the AC generator.
Remove the starting motor. Remove the oil pump. Then remove the cam
chain tensioner bolt. Remove the cam chain tensioner. Use special
tools to remove the starting driven gear.11

Remove the crankcase positioning bolts. Separate the right
crankcase and the left crankcase.

Be careful not to damage the joint face.

Remove the gasket and the dowel pins.

Remove the crankshaft from the crankcase. Take out the cam
chain.

Remove the gasket on the crankcase joint face, be careful to not
damage the joint face.

Remove the oil seal from the left crankcase.

Remove the oil seal from the right crankcase.

12

CRANKSHAFT AND CRANKCASE INSPECTIONReplace the whole set of the
crankshaft if serious wear is found while inspecting. Measuring the
axial trend clearance of the big end of the connecting rod. When
measuring, put the large end of the connecting rod close to the
crank, and insert the feeler gauge between the other side and the
crank, for the correct end play.Service Limit 0.55mm

Measure the radial trend (X,Y) clearance of the big end of the
connecting rod.Service Limit 0.05mm

Measure the main shaft journal jump of the crankshaft. If the
crank journal jump is too much it will cause the engine to shake
abnormally, and shorten the lift of the engine, so it must be
examined carefully when inspecting.Service Limit 0.10mm(A=90)
0.10mm(B=105)

Examine if there is any loose, or unusual sound when the crank
journal bearing turns, if there is, the whole set should be
changed. After cleaning the crankcase, inspect if there is any
damage. Inspect if the joint face of the crankcase is smooth and
clean, and notice if it will affect the sealing performance between
the left and right crankcase while reassembling. After the above
inspection, if the crankcase has some surface damage, use oilstone
to renish it. If damage is too severe, replace the cover. Because
the right and left crankcase axle hole must be concentric, they
should be replaced at the same time.

CRANKSHAFT AND CRANKCASE INSTALLATION Mount the crankcase oil
seal. Put the cam chain into the left crankcase. Put the crankshaft
into the left crankcase.

Pay attention to avoid damaging the oil seal with the cam
chain.

13

Mount the new dowel pins and gasket on the left crankcase. Then
join the right crankcase and left crankcase together. Tighten the
crankcase positioning bolts.Tightening Torque 1.98 lbs/m

Mount the starting driven gear Mount the cam chain tensioner
Mount the new O-ring on the cam chain tensioner bolt. Apply some
oil on the O-ring. Tighten the cam chain tensioner bolt.

The O-ring must be mounted in the groove.

VALVE MECHANISM INSPECTION AND SERVICINGThe picture shows the
common valve train of a four-stroke engine. This is a kind of
overhead valve train, its intake port, exhaust port, cam shaft are
all located in the cylinder head, the valves bottom up over the
combustion chamber.

GENERAL INTRODUCTIONThe four-stroke engine completes its four
stroke with one piston stroke. Intake stroke Compression stroke
Expansion stroke Exhaust stroke

14

VALVE CLEARANCE ADJUSTMENTValve clearance is an important
technical parameter in the valve train. In order to make sure that
during any conditions, especially when the engine is overheated, or
in cold conditions a certain clearance must be kept. This clearance
is called valve clearance. When the engine is running, the valve
clearance must not be too big or too small. So, valve clearance
adjustment is an important procedure in the valve train
maintenance. Remove the cylinder head cover.

Inspection and adjustment should be done in cool conditions
(below 35oC).

Turn the cooling fan clockwise until the mark of the timing
drive sprocket on the camshaft is at the top, dead center, and the
T symbol (or other mark) of the magneto ywheel aligns to the
crankcase mark. The crankshaft should corotate, or the exhaust port
may not be adjusted. When adjusting, loosen the lock nuts, adjust
the bolts with a valve-adjusting wrench when turned clockwise the
valve clearance decreases. And when turned counterclockwise the
valve clearance increases. Put a feeler gauge with specic sizes
between the valve and rocket to check for correct clearance. Take
out the feeler gauge, tighten the lock nuts, and then inspect the
valve clearance again. Sometimes when tightening the lock nuts the
clearance will change, so it must be rechecked for the proper
clearance.

Valve Clearance

0.08 ~ 0.12mm

15

CAMSHAFTThe camshaft is a main driving unit of the valve train.
The air inlet cam, the exhaust cam, and the cam journal are on the
shaft. It controls the intake and exhaust valve to open and close
at the correct time. Wear to the camshaft will affect engine
performance and cause excessive noise.

CAMSHAFT REMOVAL Loosen valve cover bolts and remove cover.
Remove the cam chain tensional bolt cap, and remove the O-ring.
Tighten the cam chain tensioner by adjusting bolt clockwise.

Turn the ywheel counterclockwise to make the T mark on the
ywheel align with the mark on the crankcase. When the hole on the
cam chain (timing drive chain wheel) is up, it should be at the
top, dead center.

Remove the cylinder head positioning bolt. Remove the camshaft
holder bolt cap and washer. Remove the camshaft holder and dowel
pin.

Remove the cam chain wheel from the cam chain, and remove the
camshaft.

CAMSHAFT INSPECTION Inspect the camshaft bearings for play, if
there is replace the whole set. Inspect cam surface for damage.
Measure the height of the cam.Inlet Cam Exhaust Cam 25.96mm
25.815mm

16

CAMSHAFT INSTALLATION Rotate the ywheel to align the T mark on
the ywheel with the camshaft mark. The round hole on the cam chain
wheel should be up, and the left and right sit parallel with the
cylinder head (the lobes of the camshaft are down). Then install
the camshaft on the cylinder head. Mount the cam chain on the chain
wheel. Install the dowel pins. Mount the camshaft holder, washer
and bolt cap on the cylinder head. Tighten the cylinder head bolt
and nut. While installing, apply some oil on the thread of the
camshaft holder bolt. The camshaft nuts should be tightened
diagonally in a 3-step process. After installing, adjust the valve
clearance. Turn the cam chain tensioner adjusting bolt
counter-clockwise, and release the lock. Apply oil on the new
O-ring. Mount and tighten the cam chain tensioner cover bolt. The
O-ring must be mounted properly in the groove. Replace the valve
cover gasket, and mount the cover. The valve cover gasket must be
properly mounted in the groove. Tighten the valve cover-positioning
bolt.

ROCKER ARM AND ROCKSHAFTROCKER ARM AND ROCKSHAFT REMOVAL Remove
the camshaft holder. Take out the rockshaft by removing the bolt.
Remove the rocker arm.

ROCKER ARM AND ROCKSHAFT INSPECTIONInspect if there is any
abrasion or damage on the rocker arm and rockshaft or if the oil
hole is clogged. If there is abrasion on the surface of the rocker
arm, the camshaft should also be inspected.

17

Measuring the inner diameter of the rocker arm.Service Limit
10.04mm

Measuring the outer diameter of the rockshaft.Service Limit
9.96mm

ROCKER ARM AND ROCKSHAFT INSTALLATIONRead the EX mark on the
camshaft holder, then mount the exhaust port rocker arm to the
rockshaft. After that, mount the inlet port rocker arm to the
rockshaft. Apply some oil on the rockshaft before mounting it
on.

CAM CHAIN TENSIONERThe chain tensioner must be in good working
condition for proper chain tension. 1. Cam chain 2. Cam chain
tensioner 3. Cam chain tensioner lifter. 4. Gasket 5. Cam chain
tensioner pivot 6. Cam chain guide 7. Bolt 8. Nut 9. O-ring 10.
O-ring The operational principle of the tensioner is as shown in
the picture.

As for the adjustment of the cam chain tensioner, clockwise
tightens, and counterclockwise loosens.

18

VALVE AND VALVE SPRINGVALVE AND VALVE SPRING REMOVAL Remove the
cylinder head. First remove the valve cotter with the valve
compressor, then remove the upper spring race, valve spring, lower
spring race, valve stem oil seal in turn. Remove the valve from the
other side. The removed parts should be placed in order to avoid
confusion. Its better to place the intake valve parts and exhaust
valve parts separately.

VALVE AND VALVE SPRING INSPECTION Inspect to see if the valve is
bent or burned. Inspect if the action is smooth between the valve
and the valve guide. Measure the outer diameter of the valve
stem.Service Limit 4.94mm

Measure the free length of the inner and outer valve
spring.Valve Inner spring Outer spring Inlet valve 31.2mm 34.1mm
Exhaust valve 31.2mm 34.1mm

Valve and valve spring installation Mount the spring retainer,
valve guide oil seal. It is recommended to replace the valve guide
oil seal with a new one. After applying oil on the valve stem,
mount it into the valve guide. Mount the inner and outer valve
springs. Mount the valve locker with a spring compressor. When
mounting, the twisting direction of the inner and outer springs
must be opposite. Tap on the valve gently two or three times with a
rubber hammer to make the valve and the valve lock connect well. Be
careful to not damage the valve.

19

VALVE GUIDECarbon accumulation of the valve guide will make the
valve move roughly, causing the valve to not open or close
properly. Valve guide abrasion is one of the causes of the exhaust
pipe fuming white smoke.

TO CLEAN CARBON ACCUMULATION OFF THE VALVE GUIDE Remove the
valve and springs etc. Clean the carbon accumulation with a valve
guide reamer. Generally, only turn right when using the reamer, and
do not push in or out directly with the reamer.

VALVE GUIDE INNER DIAMETER MEASUREMENTService Limit 5.03mm

Calculate the clearance between the valves stem and the valve
guide. (The inner diameter of the guide subtracted by the outer
diameter of the valve stem).

Valve Service Limit

Inlet valve 0.08mm

Exhaust valve 0.10mm

When the abrasion of the valve guide exceeds the service limit,
it should be replaced; after replacing a new valve guide, the valve
retainer must be adjusted.

VALVE GUIDE REPLACEMENT Heat the cylinder head to 100 ~ 150C The
cylinder head must be wholly and quickly heated to the specic
degree, and cannot be heated partly, or it will cause the cylinder
head to distort. The temperature is very high, two technicians are
recommended. Tap the valve guide out with a valve guide remover or
similar tool. Do not damage the cylinder joint face

20

After tapping the valve guide, you need to trim it with a
reamer. When using the reamer, cutting oil must be used. The reamer
can only be turned right, do not push in or out directly. Clean the
cylinder head, and remove the scraps generated while ramming.

VALVE SEATThe relative position between the valve seat and the
working surface of the valve is very important for the valve to
seal properly.

VALVE SEAT WIDTH MEASUREMENT Clean the carbon accumulation in
the combustion chamber. Measure the width of the valve seat with a
vernier caliper.Standard Service Limit 0.6-1.2mm 1.8mm

When abrasion causes the valve seat width to be uneven, too wide
or too narrow, it will result in bad contact between the valve and
the valve seat, and not seal tight. At this time it must be reamed
with a customized valve seat milling cutter. The valve seat milling
cutter is the customized trimming tool for the valve seat, and it
has three cutting angles, 32,45,and 60. While trimming, press the
valve seat milling cutter to make rotary motion with 40 ~ 50 N
force. Some oil must be applied on the valve seat milling cutter,
to eliminate scraping when trimming.

VALVE SEAT FINISHING Ream out the defects on the working surface
with a 45coarse tooth milling cutter. Do not ream too much.

21

Ream the upper angles of the valve seat working surface with a
30milling cutter.

Ream the lower angles of the valve seat working surface with a
60milling cutter.

Finally, ream the valve seat to the specic seat width with a
45milling cutter.

VALVE SEAT TOUCHING POSITION INSPECTIONApply a thin layer of uid
on the valve seat, and put the valve on the seat and rotate
jointly, then take out the valve and observe the contact surface on
the valve face. If the contact position is too high, then cut out
some of the upper part of the valve seat with a 32milling cutter to
reduce the working face of the valve seat. If the contact position
is too low, then cut out some of the lower part of the valve seat
with a 60milling cutter to raise the working face of the valve
seat. Finally , mill the working face of the valve seat to the
specic width with a 45milling cutter. If the valve seat still
cannot contact evenly with the valve after trimming, the valve
should be revised or replaced.

22

VALVE AND VALVE SEAT LAPPINGAfter nishing, the valve and seat
should be lapped in order to make them seal properly. Spread a thin
layer of silicon carbide on the working bevel of the vale, and use
a valve suction cup tool. Then repeatedly rotate the valve suction
cup to lap the valve and valve seat evenly, until they match
tightly.

Before lapping, clean the valve, valve seat and valve guide.
When lapping do not use too much force. During lapping, do not drop
any silicon carbide into the place between the valve lever and the
valve guide.

VALVE AND VALVE SEAT AIR IMPERMEABILITY INSPECTIONAfter lapping
the valve and valve seat, the air impermeability of the joint
surface should be inspected. Method One: same as the method of
valve seat contact position inspection. Method Two: evenly draw
several lines on the working surface of the valve with a pencil.
Put the valve into the valve seat, if the lines are all broken
after turning 1/8 ~ 1/4 ring, then it shows the air impermeability
is good. Method Three: mount the valve on the cylinder head, and ll
the inlet and exhaust vent with non ammable solvent, and preserve
for 5 minutes, if there is no leakage, the valve is seated
correctly.

23

LUBRICATION SYSTEM INSPECTION AND SERVICINGGENERAL
INTRODUCTIONThe picture shows the functional diagram of the
lubrication system. After the lubrication oil crosses the lter
screen, it is pumped by the rotator oil pump, some of it goes into
the big end of the connecting rod, and splashes on the cylinder
wall and the small end of the connecting rod; the rest goes through
some oil passages, such as the shaft neck of the camshaft, and
splashes on the cam rockshaft and cam chain. The lubrication oil
that falls back into the oil groove can be recirculated.

24

OIL SYSTEM INSPECTION AND REPLACEMENTOIL REPLACEMENT Tighten the
dipstick Remove the oil lter screen cap and the screen to let the
oil ow out.

Inspect if there is any damage to the screen and O-ring, if so,
they should be replaced. Mount the oil lter screen and the screen
covers and tighten them. Supply the application-specic oil to the
specic level.Oil Level Disassembling 0.90l Replacing 0.75l

Start the engine and run for several minutes in the idle
position to make sure there is no oil leaking. Stop the engine and
inspect if the oil level is proper.

ROTARY OIL PUMPThe oil pump is the critical component of the
lubrication system, so it should be inspected, maintained
periodically, and should be replaced as a unit when damaged
seriously.

OIL PUMP REMOVAL Remove the ywheel of the magneto. Remove the
stator coil and trigger winding.

Remove the right crankcase cover bolts and remove the right
crankcase cover. Remove the gasket and dowel pins.

25

Remove the starting reduction gear and starting clutch. Remove
the oil pump partition plate positioning bolts, and remove the oil
pump partition plate. Remove the oil pump driving gear nuts, and
remove the driving gear and chain. Remove the oil pump positioning
bolts, and remove the oil pump assembly.

Remove the screws, and disassemble the oil pump.

OIL PUMP INSPECTION Inspect the clearance between the oil pump
body and the outer rotator.Service Limit 0.12mm

Inspect the clearance between the inner rotator and the outer
rotator.Service Limit 0.12mm

Inspect the clearance between the rotator plane and the oil
pump.Service Limit 0.20mm

If the inspection result exceeds the above stated service limit,
the whole set should be replaced.

26

OIL PUMP ASSEMBLING Assemble the inner and outer rotators of the
pump, and mount the oil pump shaft. When assembling, align the
unlled corner of the oil pump shaft with the corner of the inner
rotator, and then mount.

Mount the dowel pin — you can install it after aligning the oil
pump plate with the dowel pin. Tighten the oil pump plate bolts.
After assembling, gently turn the oil pump shaft, and make sure the
oil pump can turn smoothly.

OIL PUMP INSTALLATION Install the oil pump on the crankcase.
Before installing, ll the oil pump with oil. When installing, the
arrow of the oil pump body must be pointing upwards.

Tighten the oil pump positioning bolts. Align the oil pump
driving gear with the oil pump shafts unlled corner, then mount the
driving gear and chain. Mount the driving gear-positioning nut and
tighten it.

Install the partition board and tighten bolts.

Install the starting reduction gear and starting clutch. Mount
the gasket and dowel pins.

27

Mount the right crankcase cover positioning bolt. Mount the
trigger winding and the stator coil. Tighten the right crankcase
cover positioning bolt. The bolt should be gradually diagonally
tightened in two to three steps. After nishing the installation,
inspect for any oil leaks.

FUEL SUPPLY SYSTEM INSPECTION AND SERVICINGCV CARBURETORThe CV
carburetor is a constant vacuum carburetor. The picture shows the
structure of the CV carburetor. 1. Gasket set 2. Float valve set 3.
Needle jet set 4. Float set 9. Starter valve set 10. Air cut valve
set 11. Compression coil spring 12. Screw 13. Carburetor assy. 14.
Top comp. 15. Vacuum piston comp. 16. Needle jet holder 17. Plate
clip 18. Holder cap 19. Tube A 5. Float chamber set 6. Screw set A
7. Screw set B 8. Valve plate set 20. Tube B 21. Screw 22. Screw
23. Washer screw 24. Washer screw 25. Washer screw 26. Clip 27.
Clip 28. Tube 29. Main jet 30. Slow jet

28

CARBURETOR IDLING ADJUSTMENT AIR ADJUSTING SCREW ADJUSTMENTStep
one: turn on the air adjusting screw in the turn out by the
prescribed number of turns.Turn out number of turns 2 3/4 2 1/4

Step two: adjust the throttle by adjusting the screw to the
prescribed idle rmp. Step three: left and right, adjust the air
adjusting screw slightly to nd the highest position of the rpm. Add
throttle quickly and gently (the rpm is from low to high), and
return throttle immediately, then observe 10 to 15 minutes, if the
idle remains the same.

VACUUM CHAMBERThe picture shows the structure of the vacuum
chamber of the CV carburetor.

VACUUM CHAMBER REMOVAL Remove the body cover. Remove the
automatic choke lead wire. Loosen the fuel drain bolt, and drain
the fuel in the oat chamber. Remove the fuel line, and the vacuum
pipe. Loosen the throttle cable adjusting nut and positioning nut;
remove the throttle cable. Loosen the carburetor air inlet vent
clip and the inlet manifold clip; remove the carburetor. Remove the
vacuum cover bolt, and remove the vacuum cover. Notice: move slowly
to prevent the spring from ejecting. Take out the spring, the
vacuum membrane and the plunger. Press down the holding clamp of
the needle valve top, and turn left to take out the clamp. Take out
the spring, needle valve. Do not damage the vacuum membrane.
Inspect if the needle valve is worn. Inspect if there is damage on
the vacuum membrane. Inspect if the plunger is damaged.29

VACUUM CHAMBER INSTALLATION Mount the plunger and the vacuum
membrane into the carburetor body. Push the plunger upwards in the
direction of the vacuum chamber cover to open the carburetor jet
tube. Put the spring in. Align the bulge part of the vacuum
membrane with the llister of the carburetor body, and then mount
the vacuum chamber cover. Tighten the bolt.

AUTOMATIC SIDE STARTER (CHOKE)AUTOMATIC SIDE STARTER INSPECTION
Remove the fuel hose from the carburetor. Turn out the carburetor
oat chamber drain screw, and drain the fuel in the carburetor.
Remove the automatic side starter lead wire, and remove the clip.
Remove the carburetor clamp, and remove the carburetor. Check the
condition of the connection between the two lead wires. The choke
value should be below 10V. If it exceeds the specic valve, it
should be replaced. When the engine is cold, link a hose on the
reserve supply fuel line and blow very gently. If it is obstructed
or the auto side starter is not good, it should be replaced. Remove
the auto side starter cover. Remove its positioning bolts and
pieces. Remove the auto side starter. Inspect the auto side
starting valve and fuel injection needle for wear. Inspect the
O-ring wear.

FLOAT CHAMBERFLOAT CHAMBER REMOVAL Remove the carburetor. Remove
the clamp, and remove the oat chamber. Remove the O-ring, and turn
out the oat chamber screw, remove the oat pin, and remove the oat
and oat valve. Remove the choke adjusting screw and air adjusting
screw.30

Before removing, rst tighten the two screws gently, counting the
number of turns, then remove screws. Do not use too much force, or
it will damage the air adjusting screw head surface. Remove the
main fuel injection nozzle and fuel injection needle seat.

FLOAT CHAMBER INSPECTIONInspect the oat for any damage and for
fuel in the oat. Inspect the oat valve and oat valve seat for wear.
If there is wear, it should be replaced. Clear every fuel line and
air line on the carburetor body with compressed air.

FLOAT CHAMBER INSTALLATION Install the main fuel injection
nozzle and fuel injection needle seat. Install the air adjusting
screw and choke adjusting screw, and turn them to the proper
position according to the noted number of turns while removing.
Mount the oat valve, the oat, and the oat pin. Tighten the oat pin
positioning screw.

FUEL LEVEL INSPECTION Measure the fuel level height.Fuel level
height 18.5mm

Inspect the oat for any damage and inspect the oat valve for
excess wear. Conrm that the up and down movement of the oat is
normal.

CARBURETOR INSTALLATION Inspect the oat for any damage and
inspect the oat valve for excess wear. Conrm that the up and down
movement of the oat is normal.

CARBURETOR INSTALLATION Reverse the removal procedure for
installation. After installing, make sure all carburetor linkage
and cables are in correct position, make sure carburetor is in idle
position,

31

AIR CUT VALVE (ACV) The air cut valve can avoid some abnormality
when the throttle closes too quickly, such as that the mixed gases
are too thin. The structure of the air cut valve is shown in the
picture.

AIR CUT VALVE REMOVAL Remove the air inlet manifold of the cut
valve. Remove the bolt, and remove the vacuum membrane cover, the
spring, and the vacuum membrane.

AIR CUT VALVE INSTALLATION Mount the vacuum membrane on the
carburetor. Mount the spring, the vacuum membrane cover, and the
lock bolt. The bottom side of the vacuum membrane should be aligned
with the carburetor. The top side should be aligned with vacuum
membrane.

AIR CHECK VALVEThe air check valve starts working under 50 km/h,
and impel the second air inlet to burn, and reduce CO
displacement.

AIR CHECK VALVE INSTALLATIONReverse the procedure for removal
When installing, make sure all the connecting pipes are connected
properly, and that they are not squeezed, bent, or clogged up.

32

TRANSMISSION COMPONENTS INSPECTION AND SERVICINGSTARTING
MECHANISM INSPECTION AND SERVICINGThe starting mechanism can be
divided into two types: kick starting and electric starting.

KICK RETURN STARTING MECHANISM SPIRAL SPLINE TRANSFERRING STYLE
STARTING MECHANISMThe picture shows the structure of the spiral
spline transferring style starting mechanism.

1. Kick starter spring stopping plate 2. Drive face 3. Drive
face boss 4. Movable drive face comp. 5. Weight roller set 7. Ramp
plate 8. Slide piece 9. Starting driven pulley 10. Starter gear
friction spring 11. Starter idle gear comp. 12. Starter idle shaft
13. Starter idle spring 14. Kick starter spindle comp.

15.Bush 16. Spindle bush 17. Kick starter spring 18. Special pin
20. Washer 21. Washer 22. Washer 25. Nut 26. Bolt 27. Roller 28.
Face drive collar 29. Clip

SPIRAL SPINE TRANSFERRING STYLE STARING MECHANISM REMOVAL Remove
the left crankcase cover. Remove the crankcase gasket, dowel pins.
Remove the movable driving plate (the whole set). Remove the
starting spindle washer.

33

Remove the return spring stopping plate, and remove the return
spring. Remove the whole set of starting lever. Remove the starting
idle shaft.

Disassemble the starting spindle.

Disassemble the starting idle shaft.

SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM INSPECTION
Inspect if there is any abrasion or damage of the starting spindle.
Inspect if there is any abrasion or damage of the starting idle
shaft. Inspect if there is any abrasion or damage of the starting
spindle bushing and starting idle shaft hole. Inspect if there is
any abrasion or damage of the starting spindle bushing and starting
idle shaft hole.

SPIRAL SPLINE

34

TRANSFERRING STYLE STARTING MECHANISM INSTALLATIONInstall
according to the pictures. Assemble the starting idle shaft set.
Before assembling, apply a little grease on the bore of the idle
shaft.

Assemble the starting spindle, the return spring and the spring
holding pin. A little grease should be applied on the part under
stress of the starting spindle.

Align the idle shaft holding pin with the groove of the
crankcase, then insert. Before installing, apply a little grease on
the groove of the rotary retaining spring on the idle shaft. The
rotary retaining spring should be aligned with the specic groove of
the crankcase to install. Align the scribing mark of the starting
spindle with the punching mark of the idle shaft, and then mount
the starting spindle. Hook on the two ends of the return spring.
Install the return spring stopping plate.

Install the crankcase dowel pin and gasket. Install the driven
belt and the driving plate. Install the left crankcase cover and
lock tightly. Install the starting pedal.

35

ELECTRICAL STARTING MECHANISMSTARTER MOTORThe starter motor is
actually a direct current (DC) motor, and its structure is shown in
the picture.

1. 2. 3. 4. 5. 6.

Outer Cover, Motor Rotor, Motor Base, Carbon Brush Plate,
Positive Electrode Carbon Brush, Positive Electrode Carbon Brush,
Negative Electrode

7. O-ring 8. O-ring 9. Bolt 10. Spring Washer 11. Washer 12.
O-ring

STARTER MOTOR REMOVALBefore removal, rst shut off the main
switch, and disconnect the battery connecting wire. Then press the
starting button, at this time the starter motor should not run.
This should be done to insure safety. Remove the starter motor lead
wire clamp. Remove the starter motor holding bolt, and remove the
starter motor.

Roll up the rubber water- resistance cover, and remove the
starter motor joint. Remove the motor case bolt, the carbon brush
seat, and the motor case etc.

36

ARMATURE INSPECTION Inspect the armature surface for uneven
wear, damage or burns (changing color). When there are metal nes
attached to the gap of the armature surface, use a cleaning cloth
to remove them. Please do not use sandpaper to grind, and also do
not wash it in any solvent which can dissolve or damage its
insulation. Measure the conducting condition of the armature coil
according to the picture. It should be conductive. Measure the
conducting condition between the armature coil and the armature
according to the right picture. It should be non-conductive. If its
not, it should be replaced.

CARBON BRUSH INSPECTION Inspect the insulating condition between
the connecting wire terminal and the starter motor case, and it
should be nonconductive.

Inspect the conducting condition between the connecting wire
terminal and the carbon brush, and it should be conductive. Measure
the length of the carbon brush. Replace it if it exceeds service
limit.

Measure the insulating condition of the carbon brush bracket,
and it should be non-conductive, if not, it should be replaced.

Inspect the needle bearing in the carbon brush base, it should
be able to move smoothly with no play. Inspect the dust seal for
wear or damage. If damaged, it should be replaced.37

STARTER MOTOR INSTALLATION Apply some oil on the dust seal.
Install the carbon brush on the carbon brush base. Apply a little
oil on the moving part of the armature ends. Put the carbon brush
into the bracket, and then install the carbon brush base.

Do not damage the contact area of the carbon brush and the
armature. When installing, do not damage the lip of the dust seal.
Mount the new O-ring on the carbon brush base. Install armature
into starter motor case, marking sure not to damage the carbon
brushes. Tighten motor case bolts. Make sure the starter motor case
is free of metal particles because it is magnetic. Before
installing the starter motor on the vehicle after assembling it,
rst connect the lead wires and check that the motor is running
normally.

Apply oil on the O-ring, and install the starter motor. Tighten
holding bolts.

38

The picture shows the structure of the reduction mechanism.

REDUCTION MECHANISM

1. Starter reduction gear 2. Starter reduction gear shaft 3.
Starting clutch gear comp 4. Starting clutch outer comp. 9. Starter
motor lead wire 10. Clamp 11. Clamp 12. Bolt 13. Nut 15. Dowel
pin

5. Flange starting clutch 6. Starting clutch roller spring 7.
Spring holder 8. Starter motor 16. Key woodruff 17. Roller 18.
Needle bearing 19. O-ring 20. Screw 21. Bolt

REDUCTION GEAR INSPECTION Remove the starting clutch. Remove the
reduction gear to inspect its wearing degree. Measure the inner
diameter of the reduction gear shaft. It should be replaced when
the diameter is more than 10.05mm. Measure the outer diameter of
the reduction gear shaft. It should be replaced when the diameter
is less than 9.94mm.

ENGAGING MECHANISM

39

STARTING CLUTCH REMOVAL Remove the right crankcase cover. Remove
the left crankcase cover. Hold the drive face with the universal
set wrench. Remove the starting clutch xing nut. Notice that the
thread of the xing nut should be lefthanded rotation. Remove the
starting clutch (the whole set).

STARTING CLUTCH INSPECTION Inspect if the movement between the
clutch and the driving gear is normal. The driving gear should
smoothly turn clockwise, and should not move counterclockwise.

Inspect if there is any abrasion or damage on the contact
surface between the driving gear and the needle bearing. It should
be replaced if the surface is damaged. Measure the inner diameter
of the driving gear. It should be replaced when the diameter is
more than 32.06mm. Inspect the condition of the needle bearing. It
should be replaced if there is any damage. Inspect if there is any
abrasion or damage on the contact surface between the outer clutch
component and the roller. Inspect if there is any injury on the
roller. Inspect if there is any distortion of the spring. If the
damage is serious, it should be replaced. Measure the inner
diameter of the ange clutch. It should be replaced when the
diameter is more than 27.94mm.

40

STARTING CLUTCH INSTALLATION Install the spring, the roller and
the top pin on the body of the clutch. Align the dowel pin on the
ange clutch with the hole on the clutch body, then install. Apply
some thread lock on the outer clutch component bolt and tighten.
Apply some oil on the needle bearing and the driving gear, and then
put the outer clutch component on. Align the groove of the woodruff
key on the crank, and install the staring clutch. Apply some oil on
the reduction gear and the reduction gear shaft, then install. Hold
the drive face with the universal wrench, at the same time fasten
the clutch nut. Notice that the thread of the nut should be
left-handed rotation. Install the right crankcase cover. Install
the left crankcase cover. Take the reduction mechanism and the
engaging mechanism as a whole unit and it is called the
starter.

CONTROLLING MECHANISMSTARTER RELAY INSPECTION Turn the main
switch to the ON position, and press down the starting motor
button, and listen for a click sound. If there is, it is normal; if
there isnt, follow the below procedures to inspect. Inspect to see
if the brake switch is conductive. At this time, turn the main
switch on and hold the brake lever. The battery voltage should be
at 12 volts. Measure the voltage between the inlet line (the
green/yellow line) starting relay and the ground wire of the body.
The voltmeter reading should be close to the magnitude of voltage
between the two ends of the battery. If not, then the brake switch,
its wire or the wire connector is damaged. Check that the start
button is conductive. At this time, remove the starting relay inlet
line (the green/yellow line). Connect the yellow/red line with the
ground wire, and press the start button. It should be conductive
between the yellow/red line and the ground wire. If its not
conductive the start button, its wire, or the wire connector is
damaged.41

Check the working condition of the starting relay. At this time,
remove the starting relay. Connect the C end the D end of the
starting relay with the battery, and the A and B end with the
multimeter. The battery voltage should be at 12n volts. At this
time the multimeter should indicate a conductive condition, or the
starting relay is not good.

BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICINGGENERAL
INTRODUCTIONThe belt driven CVT mechanism is made up of two belt
pulleys (the drive belt pulley and the driven belt pulley) whose
diameter can be changed, and a notched driven belt. The driving
belt pulley is mounted on the engine crankshaft, and the driven
belt pulley connects with the rear driven mechanism.

Its basic operational principle is to realize automatic CVT by
the diameter changes (the transmission ratio changes) of the
driving and driven belt pulley. When the diameter of the driving
belt pulley changes from small to big, proportionally the diameter
of the driven belt pulley changes from big to small (because the
perimeter of the driven belt is constant), at this time the speed
increases. On the contrary, the speed decreases.

42

The structure of the driving belt pulley is shown in the
picture.

The picture shows the working theory of the driving belt
pulley.

The picture shows the structure of the driven belt pulley. The
clutch showed in this picture is the automatic dry centrifugal
weight clutch.

43

DRIVE BELT PULLEYDRIVE BELT PULLEY REMOVAL Remove the left
crankcase air pipe lock bolt. Remove the kick starter, and remove
the left crankcase xing bolt. Remove the left crankcase cover.
Remove the gasket and the dowel pin. Hold the drive plate with a
universal wrench, and then remove the nuts and gasket on the drive
plate shaft. Remove the drive plate. Remove the driven belt from
the drive plate.

Remove the movable drive plate (the whole set).

Remove the ramp plate.

Remove the centrifugal rollers.

DRIVE BELT PULLEY INSPECTION Inspect if there is any abrasion or
damage to the centrifugal roller. Measure the outer diameter of the
centrifugal roller.Service Limit 17.00mm

44

Measure the inner diameter of the movable drive plate.Service
Limit 24.06mm

Inspect if there is any abrasion or damage of the drive plate
hub. Measure the outer diameter of the drive plate hubs movable
surface.Service Limit 23.94mm

DRIVE BELT PULLEY INSTALLATION Apply some grease evenly in the
movable drive plate. Put the centrifugal rollers into the movable
drive plate.

Install the ramp plate.

Put the drive plate hub into the drive plate.

Install the movable drive plate on the crankshaft.

45

Enlarge the driven plate belt groove, and mount on the driven
belt. Mount the other end of the driven belt on the drive plate
hub. Mount the drive plate, the drive plate washer, and nut.

Hold the drive plate with a multiuse holder to make it
unmovable. At the same time fasten the nut on the shaft. Do not
allow any grease or oil to get on the surface of the movable drive
plate and the driven belt.

CLUTCH REMOVAL Remove the left crankcase cover.

CLUTCH

Remove the drive plate and the driven belt. Hold the clutch
friction plate with a multiuse holder, and remove the nut. Remove
the clutch friction plate.

CLUTCH INSPECTION Inspect if there is any abrasion or damage on
the clutch friction plate. Measure the inner diameter of the clutch
friction plate.Service Limit 125.5mm

Inspect if there is any abrasion or damage of the clutch
centrifugal weigh friction piece. Measure the thickness of the
clutch centrifugal weight friction piece.Service Limit 1.5mm

CLUTCH DISASSEMBLING If the centrifugal weight set needs to be
replaced, you must disassemble the clutch. When the friction piece
is worn, it should be replaced with the centrifugal weight
set.46

Remove the clutch friction plate. Remove the whole set of
clutch/driven plate. Compress the driven pulley spring with the
clutch spring compressor, and at the same time remove the nut on
the shaft. Disassemble the clutch with the driven pulley. Remove
the circlip, and remove the connecting piece. Remove the clutch
centrifugal weight set and the spring.

CLUTCH INSTALLATION Mount the clutch damper rubber onto the
drive plate pin. Mount the new clutch weight set and spring on the
drive plate. Install the connecting piece, the circlip, and the
bottom plate. Finally reverse the removal procedure for
installation. When assembling the clutch and the driven plate, you
must use a clutch spring compressor, or it will damage the spring.
No grease on the driven pulley.

47

DRIVEN BELT PULLEYDRIVEN BELT PULLEY REMOVAL After removing the
clutch friction plate, remove the guide pin, the roller and the
movable driven plate.

Remove the oil seal on the movable driven plate.

DRIVEN BELT PULLEY INSPECTION Measure the free length of the
driven belt pulley spring.Service Limit 163.7mm

Inspect if there is any abrasion or damage on the driven
plate.

Measure the outer diameter of the driven plate pulley
hub.Service Limit 33.94mm

Inspect of there is any abrasion or damage of the movable driven
plate.Service Limit 34.06mm

Inspect if the groove of the guide pin is worn.

48

DRIVEN PLATE BEARING REPLACEMENTIf the driven plate needle
bearing or the ball bearing are loose, damaged, or make unusual
sounds, they should be replaced. Remove the needle bearing from the
driven plate. The removed bearing cannot be reused.

Remove the circlip from the driven plate. Drive the ball bearing
out.

The removed bearing cannot be reused.

Apply some grease on the new ball bearing. Drive the ball
bearing into the driven plate with its front face upwards. Mount
the circlip. Apply grease evenly on the inner wall of the driven
plate. Use the prescribed grease. Drive in the new needle bearing
with its mark upwards. Use the specic tool. Apply grease around the
bearing.

49

DRIVEN BELT PULLEY INSTALLATION Remove the grease on the driven
plate. Mount the oil seal. Apply a little grease on the O-ring.
Mount the movable driven plate into the driven plate. After
applying some grease on the roller, the guide pin, mount them into
the driven plate hole. Install the oil seal collar. Remove the
excessive grease. Do not get grease on the movable faces of the
driven plate. Assemble with the clutch and install on the left
crankcase.

TRANSMISSION BELTTRANSMISSION BELT INSPECTION Remove the left
crankcase cover. Inspect if the transmission belt is chapped or
worn. Measure the width of the belt.Service Limit 19.0mm

Replace the belt if its width is less than the above limit. When
replacing, you must use the OEM part for correct t. See the drive
pulley removal and installation procedure for the replacement.

50

The structure of the rear transmission mechanism is shown in the
following picture.

REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING

TRANSMISSION CASE OIL REPLACEMENTTRANSMISSION CASE OIL
INSPECTIONWhen inspecting the oil level of the transmission case,
use a at surface and keep the body level. Check to see if there is
oil leaking around the transmission case. After the engine stops,
remove the transmission case oil level bolt. Observe the oil level,
the oil level should be parallel with the observing hole. When the
oil level is too low, add until the oil ows from the level screw.
Use the same kind of oil according to the prescribed brand and
specication. Mount the transmission case oil level bolt and the
washer. Inspect the bolt oil seal to see if it is damaged.

TRANSMISSION CASE OIL REPLACEMENT Remove the transmission case
oil level bolt. Remove the oil drain bolt to drain the oil. Mount
the drain bolt and its oil seal and fasten.51

Supply the oil with the prescribed specication and oil level.
Mount the level bolt. After replacing the oil, inspect for any oil
leaks.

TRANSMISSION CASETRANSMISSION CASE REMOVAL Remove the driven
belt pulley. Drain out the oil in the transmission case. Remove the
drive sprocket. Remove the bolt, and remove the transmission case
cover. Remove the gasket and the dowel pin. Remove the nal gear,
the nal gear shaft, and remove the sub shaft/sub shaft gear.

TRANSMISSION CASE GEAR INSPECTION Check if the sub shaft/sub
shaft gear is damaged or worn.

Check if the nal gear or the nal gear shaft is damaged or
worn.

52

BEARING ON THE TRANSMISSION CASE COVER REPLACEMENTWhen removing
or installing the bearing on the transmission case cover, you must
use the specic tool shown in the picture.

Press the driven belt pulley shaft out of the transmission
cover.

Remove the oil seal and drive out the bearing.

Remove the nal gear shaft bearing.

Remove the sub shaft bearing.

Drive in the new ndal gear shaft and bearing. When driving in
the nal gear shaft bearing, keep the bearing parallel. The same is
required when installing the sub shaft bearing and the driven
pulley shaft bearing.

Drive in the new sub shaft bearing.

Drive in the driven pulley shaft bearing.

53

BEARING ON THE LEFT CRANKCASE BODY REPLACEMENTWhen removing or
installing the bearing on the left crankcase body, you must use the
specic tool. Inspect if the bearing and oil seal on the left
crankcase for wear or damage. If it is damaged, it must then be
replaced. Remove the oil seal. Drive out the nal gear shaft
bearing. Remove the sub shaft bearing.

Remove the driven belt pulley shaft bearing.

Drive in the new driven belt pulley shaft bearing.

Drive in the new sub shaft bearing.

Drive in the new nal gear shaft bearing.

54

Install the driven belt pulley shaft on the transmission case
cover.

Drive in the transmission case cover oil seal.

Mount the sub shaft/sub shaft gear and the nal gear shaft into
the left crankcase.

Mount the nal gear on the nal gear shaft.

Install the new dowel pin and gasket. Install the transmission
case cover and bolt.

Mount the driven pulley/the clutch set.

Mount the drive pulley, the transmission belt, and the left
crankcase cover. Fill the transmission case with oil.

55

OIL SYSTEM INSPECTION AND SERVICING1. Check all lines for leaks
and cracks. 2. To replace an oil line rst make sure the end is cool
and that the oil inside is not hot. Loosen the bolt on both ends of
the hose, and take the hose out and replace with new hose,
retighten bolts. 3. Oil lter, replacement, and changing of the oil.
a. On the bottom of the engine block case there is a 1/2 bolt head.
Turn this counter clock wise to loose and drain oil. After the oil
is drained, replace and retighten bolt clockwise. b. The oil lter
is removed by turning clockwise by using a coil lter wrench, when
remove. Fill the new one with oil 2 mm from the top. Replace the
oil cooler turning counterclockwise. Engine MFG suggest that you
change your oil and lter after 40 hours of use.

Electric SystemCHARGING SYSTEM INSPECTION AND SERVICINGELECTRIC
LEAKAGE TESTING Turn the main switch to the OFF position.
Disconnect the negative ground wire from the battery. Connect the
positive end of the ammeter with the negative end of the battery.
Connect the negative end of the ammeter with the ground wire. Test
the electric leakage. In general, it demands the number should be
less than 1 m A; if it is unusual, check if there is a short
circuit of the main switch and the main wiring.

CHARGING STATUS INSPECTION Install the fully charged battery.
Connect the voltmeter between the binding posts of the
battery.56

Remove the fuse, and connect the ammeter with two ends of the
fuse. Connect the tachometer to the engine (its not needed when
there is rpm indicator on the vehicle). Start the engine, and
accelerate slowly, measure the charging voltage and current.
Charging voltage (V) Charging current (A) 13.5 ~ 15.5 0.5

*Measuring condition: 5000 r/min If the voltage is not in the
range of the above-specied value, please inspect the voltage
regulator.

BATTERYThe battery is an important component of the electric
system. The battery used on the vehicle is a maintenance-free
battery. For long periods of storage, the battery will discharge.
It should be charged every 3 months. After 2 ~3 years of regular
usage, the capacity of the battery will lessen and will need
charging. Replace with the same type of battery.

BATTERY REMOVALShut down the main switch to make sure no
electric current goes through the vehicle. Disconnect the negative
battery lead wire rst. Disconnect the positive battery. The
disconnecting order cannot be reversed. When disconnecting the
positive cable, do not touch the body of the vehicle with the
removal tool, or it will short circuit and ignite gas that will
damage the battery.

BATTERY INSTALLATIONConnect the positive cable rst, then connect
the negative cable.

BATTERY OPEN-CIRCUIT VOLTAGE INSPECTIONDisconnect the cable on
the battery terminals. Disconnect the negative pole rst, then the
positive pole. Measure the voltage between the two poles of the
battery. Full charging Under charging 13.1V 12.3V

57

BATTERY CHARGING Lift the battery out of the vehicle. Connect
the positive pole of the charger with the positive pole of the
battery. Connect the negative pole of the charger with the negative
pole of the battery. Charge the battery for the charging time
marked on the battery. Unless it is urgent, do not use fast
charging. There should be no smoking or open re near the battery
when charging. At the beginning or the end of charging, turn off
the charger rst, in order to avoid the connecting part arcing.
Measure the voltage 30 minutes after charging is nished, and it
should reach the specied value, or its needed to recharge.

Charging Current Charging Time Charging Result

Normal Fast Normal Fast

0.7 A 3.0 A 5-10 hours 30 minutes Open-circuit voltage 12.8V

PRIMARY COILThe picture shows the structure of a common
generator.

1. 2. 3. 4. 5.

Cooling Generator assembly Flywheel comp. Stator comp.
Washer

6. Bolt 7. Nut 8. Bolt 9. Bolt

58

PRIMARY COIL INSPECTIONWhen the inspection work is done on the
engine there is no need to remove the generator. Remove the 4- core
connector of the generator. Measure the resistance value between
the white wires of the generator and connecting wire of the vehicle
body.

Standard value

0.2 ~ 0.4 (20C)

When the actual value is more than the standard value, the coil
should be replaced.

GENERATOR REMOVAL AND INSPECTIONGENERATOR REMOVAL Remove the
cooling fan cover bolt and screw. Remove the cooling fan cover.
Remove the cooling fan bolt, and remove the cooling fan. Hold the
ywheel with a universal holding wrench, at the same time remove the
ywheel nut.

Remove the ywheel with a ywheel puller, and remove the solid
key.

59

Remove the generator wire connector. Remove the generator wire
holder. Remove the generator coil bolt. Remove the generator wire
rubber bushing from the right crankcase. Remove the coil set. Do
not damage the coil when removing.

GENERATOR INSTALLATIONReverse the removal procedure for
installation.

When installing the ywheel, make sure there are no metal pieces,
such as bolts or nuts, attachinging to the inner wall of the
ywheel. After the installation is nished, start the engine to
inspect and adjust the ignition timing.

REGULATE RECTIFIERMAIN WIRING SUB ELECTRIC CIRCUIT CONDITION
INSPECTIONDo the voltage regulate rectier inspection procedure in
two steps: First inspect the main wiring sub electric condition,
and then inspect the voltage regulator. Second, inspect only when
engine is cold. Remove the 4-core connector of the regulate
rectier. Measure the conducting status between the main wiring
terminals according to the previous wiring diagram.

60

Connecting type Battery (the red wire) Vehicle body Connecting
wire (the green wire) Vehicle body Lighting wire (the yellow wire)
Vehicle body (remove the resistor, side auto starter plug, and turn
the lighting switch to OFF) Charging wire (the white wire)- Vehicle
body

Normal condition Battery voltage value Conductive Generally is
0.1 ~0.8

Generally is 0.2 ~ 2.0

W (White) W (White) Y (Yellow) R (Red) G (Green)

Y (Yellow) 5 ~ 100K

R (Red) 3 ~ 100K

G (Green) 5 ~ 100K

REGULATE RECTIFIER INSPECTIONWhen the main wiring sub electric
circuit condition is normal, inspect the regulate rectier. Check
that the regulate rectier plug contacts well. Measure the
resistance value between every regulate rectier terminal. If the
resistance value between the terminals is unusual, replace the
regulate rectier.

RESISTORRESISTOR RESISTANCE VALUE MEASUREMENTMeasure the
resistance value between the resistor wire and the vehicle body. It
is normal when the actual value is in the range of 1 value marked
on the diagram or the resistor, if not, it should be replaced.

61

IGNITION SYSTEM INSPECTION AND SERVICINGThe circuit working
principle is shown in the picture.

IGNITION TIME INSPECTIONThe CDI ignition system has already been
adjusted in the factory, so there is no need to readjust it. If
inspecting ignition function is necessary, use the following steps
to inspect ignition timing. Remove the ignition timing hole cover
(or remove the fan cover). Rotate the generator rotor, and align
the F mark on the rotor with the crankcase timing ignition mark.
Clip the ignition timing indicator light wire clip on the high-
voltage end of the ignition coil. Start the engine and let it idle.
At this time, observe if the mark on the crankcase aligns with the
F mark on the rotor. If the difference is between 3it indicates
correct ignition timing; on the contrary, if it is off3, it should
be adjusted. Slowly increase the engine rpm (when the 150 model
increases to 5000 r/min), at this time, if the mark on the
crankcase aligns with the rotor ignition advance angle mark, the
advance angle device is good; if not, it should be adjusted or
replaced. When adjusting, the trigger winding can be loosened to
adjust the angle between it and the ignition charging coil to
adjust the ignition time.

IGNITION SYSTEM INSPECTION When the spark plug does not spark,
rst inspect the wires, and if the connecting part is loose, or
contacts bad etc; you can follow the electric circuit and use the
method of measuring the voltage of every point to nd out the
trouble. Please refer to the previous picture for the following
inspection. Remove the old spark plug, and install a new one, if
plug is bad.

62

It is important that every electric circuit wire connects
correctly. It is important that the cylinder compression pressure
is normal. Connect the negative end of the multimeter with the
positive connecting iron of the primary ignition coil (black /
yellow wire). Press the starting button or use the kick-starter,
and read the voltage value on the multimeter, the biggest voltage
value should be above 112V. When measuring the voltage, do not
touch the metal part of the multimeter with nger, or an electric
shock can occur. Remove the 4-core and 2-core connector of the CDI
component. Connect the positive end of the multimeter with the
ignition charging coil (black/red wire end) of the 2-core
connector, and the negative end with the ground wire end (green
end) of the 4-core connector. Press the starting button, or use the
kick-starter, and measure the highest voltage of the ignition
charging coil, it should be more than 122V. When the highest
measured voltage of the ignition charging coil is not normal, then
disconnect the generator connector to take further measurements. If
it is measured that the CDI component end is abnormal, however, the
terminal voltage of the generator is normal, then there is a bad
wire or bad connection. When both are not normal, then it is a bad
ignition charging coil. Remove the 4-core and 2-core of the CDI
component. Connect the positive end of the multimeter with the
trigger winding (green/red wire terminal) on the 4-core connector,
and the negative end with the green wire terminal on the 4-core
connector. Press the starting button, or kickstarter, and measure
the highest voltage of the trigger winding, which should be more
than 2.1V. When the highest measured voltage of the trigger winding
is not normal, then remove the generator connector, and take
further measurements. If the measured terminal voltage of the CDI
component is not normal, the generator terminal voltage is normal,
then there is a bad wire or bad connection. If both are not normal,
then it is a bad trigger winding.

IGNITION CHARGING COIL Remove the connector of the ignition
charging coil wire. Measure the resistance value between the
ignition charging coil (black/red wire) and the body ground
wire.Standard Value 300 ~1000 (20C)

When the actual value is more than the standard value, it should
be replaced.

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TRIGGER WINDING Remove the connector of the trigger winding
wire. Measure the resistance value between the trigger winding
(green/red wire) and the body ground wire.Standard Value 40 ~300
(20C)

When the actual value is more than the standard value, it should
be replaced.

CDI COMPONENTIt is similar to the regular inspection, the CDI
component inspection is also divided into two steps: First inspect
every wiring, winding or coil connected with CDI, then inspect the
CDI component.

REMOVE THE CDI COMPONENT. Check to see if the connector is loose
or eroded. Inspect the conduction and the resistance value of the
main switch, the ignition charging coil, the trigger winding, and
the ignition coil. When the main switch is in OFF position, it
should be conducted, and the resistance value of every coil should
be the standard value. Inspect the resistance value between every
CDI component terminal. If the actual value is not in the range of
the value in the chart, then the CDI component is faulty.

CDI COMPONENTSW (B/W) SW (B/W) EXT (B/R) PC (G/R) E (G or G/W)`
IGN (B/Y) 0.5 ~ 50 10 ~ 1000 0.5 ~ 50 EXT (B/R) 100 ~ 10 ~ 1000 0.5
~ 50 PC (G/R) 50 ~ 100 ~ 1 ~ 10 E (G or G/W) 100 ~ 1 ~ 100 IGN
(B/Y)

B- Black

W- White

R-Red

G-Green

Y- Yellow

The CDI component can also be inspected and measured with the
CDI testing instrument. Please carefully read the instrument
specication to know how to properly operate. Connect CDI component
with the special wire of the testing instrument. Observe the spark
condition on the instrument when the switch is turned on different
positions (OFF, P, EXT, ON1, ON2)

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IGNITION COILIGNITION COIL REMOVAL Remove the spark plug cap.
Remove the primary ignition coil wire. Remove the ignition
coil-positioning bolt, and remove the ignition coil.

IGNITION COIL INSTALLATION Reverse the removal procedure for
installation. When installing, connect the black/yellow wire of the
primary ignition coil with the black/yellow connector of CDI, and
the green wire the green connector of the CDI.

PRIMARY IGNITION COIL INSPECTIONStandard Value 0.1 ~ 1.0K
(20C)

If the resistance value is , it indicates the coil is bad and
should be replaced.

SECONDARY IGNITION COIL INSPECTIONInstall the spark plug cap,
and measure the resistance value of the secondary ignition
coil.Standard Value 7 ~ 9K (20C)

If the resistance value is in the standard range, it is good;
however, indicates the coil is bad. Remove the spark plug cap, and
measure the resistance value of the secondary ignition
coil.Standard Value 2 ~ 4K (20C)

The resistance value is in the standard range indicates it is
good; however, indicates the coil is bad. The ignition coil also
can be inspected and measured with the ignition testing instrument.
Please operate properly according to the instructions. Set the
measuring switch of the ignition coil on the 1.2V position, and
connect the ignition coil. Turn the switch of the testing
instrument to the ON position, observe the spark over window and
inspect the spark over situation of the ignition coil. If it is a
normal consistent spark, it is good; if the spark does not ash
consistently, it is not good.

SPARK PLUG Clean the carbon around the spark plug to prevent it
from dropping into the cylinder Remove the spark plug.65